Methods and Systems for Removing Material from Bitumen-Containing Solvent

ABSTRACT

Methods and systems for preparing bitumen-laden solvent for downstream processing are described. The bitumen-laden solvent can be treated with various materials, such as water and emulsion breakers, followed by treating the bitumen-laden solvent in a desalter. The desalted bitumen-laden solvent can then be subjected to downstream processing, such as upgrading in a nozzle reactor.

This application claims priority to U.S. Provisional Application No.61/579,948, filed Dec. 23, 2011, the entirety of which is herebyincorporated by reference.

BACKGROUND

Extraction of bitumen from bituminous material such as oil sands can becarried out using a variety of different processes. Many extractionprocesses use solvent capable of dissolving bitumen as a means forextracting bitumen from bituminous material. As a result, an initialproduct of many extraction processes is a bitumen-containing solventstream. Bitumen-containing solvent streams generally include solventhaving a content of bitumen dissolved therein.

Many bitumen-containing solvent streams also include other components inthe solvent stream. For example, many bitumen-containing solvent streamswill include non-bitumen solid particles. The non-bitumen solidparticles can include a variety of different materials, includinginorganic salts, silica, and coal particles. These solid particles areoften present in the bitumen-containing solvent streams because they arepresent in the material from which the bitumen-containing solvent wasobtained. For example, when the bituminous material is oil sands, theoil sands material will generally include inorganic salts and silica. Inthat event, the solvent used to extract bitumen from the oil sands willalso usually pick up a portion of these solid particles.

Generally speaking, the presence of this solid material in thebitumen-containing solvent is undesirable. A primary reason why thesolid material is undesirable is that the solid material can cause avariety of issues in downstream processing of the bitumen-containingsolvent material. For example, when the bitumen-containing solventmaterial is run through heat exchangers prior to being separated in adistillation column, the solid material can leave deposits on and foulthe heat exchangers. Also, when bitumen-containing solvent is heatedprior to distillation, some solid materials can be converted tocorrosive material.

For example, inorganic salts present in bitumen-containing solvent, suchas magnesium chloride, can convert to hydrochloric acid when exposed toelevated temperatures. The hydrochloric acid can subsequently damagedownstream processing equipment, such as overhead condensers used afterdistillation. In another example, solid materials in bitumen-containingsolvent upgraded in a nozzle reactor can act as coke precursors that caneventually plug the nozzle reactor.

Various attempts have been made to remove solid material frombitumen-containing solvent streams prior to downstream processing. Forexample, both filtration systems and centrifuges have been used to treatbitumen-containing solvent with the aim of removing non-bitumen solidmaterial. One of the biggest problems faced with both filtration systemsand centrifuges is the difficulties with scaling up this equipment whenlarge volumes of bitumen-containing solvent need to be treated. In bothinstances, scale up of this equipment can be commercially unfeasible.Additionally, with respect to centrifuges, the separation of solidsusually provides less than desirable results, and the separationtypically has to occur on a batch basis rather than on a more desirablecontinuous basis.

SUMMARY

The applicants have invented an improved method and system for removingmaterial, such as solid particles, from a stream of bitumen-containingsolvent. In some embodiments, the method can include the steps of: i)providing a bitumen-containing solvent stream; ii) mixing thebitumen-containing solvent stream and a water stream; iii) introducingthe mixture of the bitumen-containing solvent stream and the waterstream in to a desalter, such as to remove, for example, solid particlesfrom the mixture; iv) removing a desalted bitumen-containing solventstream from the desalter; and iv) subjecting the desaltedbitumen-containing solvent stream to downstream processing. In someembodiments, the downstream processing includes injecting the desaltedbitumen-containing solvent stream into a nozzle reactor in order toupgrade the bitumen component of the desalted bitumen-containing solventstream.

In certain embodiments, a system for removing solids from a stream ofbitumen-containing solvent and upgrading the bitumen component of theresulting stream can include a) a desalter having a bitumen-containingsolvent stream inlet and a desalted bitumen-containing solvent streamoutlet, and b) a nozzle reactor having a feed material inlet that is influid communication with the desalted bitumen-containing solvent streamoutlet of the desalter. In some embodiments, the system can also includea mixing vessel upstream of the desalter for mixing water and abitumen-containing solvent stream.

Various advantages can be achieved from the methods and systemsdescribed herein. For example, in some embodiments, the methods andsystems can provide for improved separation of solid particles,including inorganic salts and other undesirable solid material such assilica and coal particles, from bitumen-containing solvent streams. Incertain embodiments, the methods and systems can be performed/operatedcontinuously, and it can be commercially feasible to scale up thedesalter used in the methods and systems so that the methods and systemscan continuously process large volumes of bitumen-containing solvent.

It is to be understood that this Summary is provided to introduce aselection of concepts in a simplified form that are further describedbelow in the Detailed Description. As a result, this Summary, and theforegoing Background, are not intended to identify key aspects oressential aspects of the claimed subject matter.

In addition, these and other aspects of the presently described methodsand systems will be apparent after consideration of the DetailedDescription and accompanying Figures. It is to be understood, however,that the scope of the systems and methods described herein shall bedetermined by the claims as issued and not by whether given subjectmatter addresses any or all issues noted in the Background or includesany features or aspects recited in this Summary.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the presently describedsystems and methods, including the preferred embodiments, are describedwith reference to the following figures, wherein like reference numeralsrefer to like parts throughout the various views unless otherwisespecified.

FIG. 1 is a flow chart detailing steps of a method of separatingnon-bitumen solid particles from a bitumen-containing solvent streamaccording to various embodiments described herein;

FIG. 2 is a cross-sectional view of a desalter suitable for use invarious embodiments described herein;

FIG. 3 is a block diagram illustrating a system suitable for use incarrying out some of the methods disclosed in this specification;

FIG. 4 shows a cross-sectional view of some embodiments of a nozzlereactor suitable for use in various embodiments of the systems andmethods described herein;

FIG. 5 shows a cross-sectional view of the top portion of the nozzlereactor shown in FIG. 4;

FIG. 6 shows a cross-sectional perspective view of the mixing chamber inthe nozzle reactor shown in FIG. 4;

FIG. 7 shows a cross-sectional perspective view of the distributor fromthe nozzle reactor shown in FIG. 4;

FIG. 8 shows a cross-sectional view of some embodiments of a nozzlereactor suitable for use in various embodiments of the systems andmethods described herein; and

FIG. 9 shows a cross-sectional view of the top portion of the nozzlereactor shown in FIG. 7.

DETAILED DESCRIPTION

With reference to FIG. 1, a method 1000 for removing solid particlesfrom a bitumen-containing solvent stream includes a step 1100 of mixinga bitumen-containing solvent stream with a water stream, a step 1200 ofintroducing the mixture of bitumen-containing solvent and water into adesalter, a step 1300 of removing a desalted bitumen-containing solventstream from the desalter, and a step 1400 of subjecting the desaltedbitumen-containing solvent stream to downstream processing. The removalof the solid particles in the desalter reduces or eliminates severalissues that can arise when downstream processing is carried out onbitumen-containing solvent streams including solid material such asinorganic salts and silica.

In step 1100, a bitumen-containing solvent stream is mixed with a waterstream. One objective of mixing the water stream and thebitumen-containing solvent stream is to provide water in which the solidparticles can become immersed and/or dissolve. In this manner, the solidparticles leave the bitumen-containing solvent stream and become a partof the water in the mixture. Due to the immiscible nature of thebitumen-containing solvent and the water, this then provides a mechanismfor separating the solids from the bitumen-containing solvent stream byremoving the water from the mixture of bitumen-containing solvent andthe water.

The bitumen-containing solvent can include a solvent in which bitumencontent is dissolved. In some embodiments, the bitumen-containingsolvent includes from 0 to 35% solvent and from 100 to 65% bitumen. Insome embodiments, the bitumen-containing solvent also includes from0.001 to 1% non-bitumen solid material.

Many different types of non-bitumen solid material can be present in thebitumen-containing solvent. Examples include, but are not limited to,inorganic salts (such as magnesium chloride, calcium chloride, andsodium chloride), silica, catalyst fines, quartz, rust, silt, metals,metal oxides, and coal particles. In some embodiments, the amount ofnon-bitumen solid material in the bitumen-containing solvent stream canrange from 0.01 to 1%. The bitumen-containing solvent may also includewater, such as from 0.01 to 2% water.

The solvent component of the bitumen-containing solvent can be anysolvent capable of dissolving bitumen. The solvent component typicallyincludes the type of solvent traditionally used in solvent bitumenextraction techniques.

In some embodiments, the solvent is an aromatic solvent, such asSolvesso 100 or Solvesso 150 (commercially available solventsmanufactured by ExxonMobil Chemical). In some embodiments, the solventis a paraffinic solvent, such as propane, butane, pentane, hexane,heptanes, or mixtures thereof. In some embodiments, the solvent is apolar solvent, such as methanol. The solvent can also include two ormore different solvents, such as any combination of the solvents listedabove.

The bitumen-containing solvent can be obtained from any suitable source.In some embodiments, the bitumen-containing solvent is obtained from abitumen extraction process that results in the production of abitumen-containing solvent. In some embodiments, this generally includessolvent bitumen extraction processes that use a solvent as part of thebitumen extraction mechanism.

In some embodiments, the bitumen extraction process from which thebitumen-containing solvent is obtained is a single solvent bitumenextraction process, such as those described in U.S. patent applicationSer. Nos. 13/558,041; 13/557,503; 13/557,842; 13/559,124; and 13/584,432each of which is hereby incorporated by reference in its entirety.

In some embodiments, the bitumen extraction process from which thebitumen-containing solvent stream is obtained is a double solventbitumen extraction process, such as those processes described in U.S.Pat. Nos. 7,909,989; 7,985,333; 8,101,067; 8,257,580; U.S. PublishedApplication Nos. 2011/0062057; 2011/0155648; 2011/0180458; 2011/0180459;2012/0152809; and 2012/0228196, each of which such Patent andApplication as applicable is hereby incorporated by reference in itsentirety.

In some embodiments, the bitumen extraction process from which thebitumen-containing solvent stream is obtained is an in-situ solventextraction process, such as those processes described in U.S. patentapplication Ser. Nos. 13/584,333 and 13/557,842, each of which suchApplication is hereby incorporated by reference in its entirety.

In some embodiments, the bitumen extraction process from which thebitumen-containing solvent stream is obtained is a Steam AssistedGravity Drainage (SAGD) process, in which steam is injected intodeposits of bituminous material to decrease the viscosity of the bitumenand allow it to flow out of the deposit via production wells. Theproduct of the SAGD process may be a mixture of water and bitumenmaterial. In some embodiments, solvents are used in conjunction with thesteam to help extract the bitumen from the bituminous deposits and/orare added to the recovered SAGD product. In such embodiments, SAGDprocesses provide a bitumen-containing solvent stream.

The water stream used in step 1100 for mixing with bitumen-containingsolvent stream can be any suitable water stream available. In someembodiments, the water is of a water wash quality. A suitable watersource includes, but is not limited to, stripped sour water providedthat ammonia and hardness levels are kept low and the pH is kept high tokeep salts from partitioning the oil phase.

The mixing of the bitumen-containing solvent and water can be carriedout in any suitable fashion. In some embodiments, the mixing of thebitumen-containing solvent and water occurs in a mixing vessel.

Any vessel capable of receiving a water stream and a bitumen-containingsolvent stream and mixing the two can be used. In some embodiments, themixing vessel is piping through which the bitumen-containing solventstream and/or water is transported. For example, the mixing can takeplace at a mixing valve where water travelling through pipelines joinsthe bitumen-containing solvent travelling through pipelines.

When a mixing vessel is used, the mixing vessel can include a waterinlet, a bitumen-containing solvent inlet, and a bitumen-containingsolvent outlet through which the mixture of water and bitumen-containingsolvent can leave the mixing vessel. In some embodiments, thebitumen-containing solvent outlet of the mixing vessel is in fluidcommunication with a bitumen-containing solvent inlet of a downstreamdesalter so that the mixture of water and bitumen-containing solventleaving the mixing vessel can be introduced into the desalter forremoval of solid material from the mixture.

The mixing of the two streams is preferably vigorous mixing such thatthe mixing promotes the movement of solid particles in thebitumen-containing solvent into the water. Any suitable equipment and/ortechnique can be used to promote vigorous mixing between the twostreams. In some embodiments, the amount of water mixed withbitumen-containing solvent stream is from 4 to 25% by volume of thebitumen-containing solvent stream.

Additional steps can be performed before, after, or as part of themixing step 1100. For example, in some embodiments, thebitumen-containing solvent can be heated prior to being mixed with thewater in step 1100. Any manner of heating the bitumen-containing solventcan be used, and in some embodiments, the bitumen-containing solvent isheated to a temperature of from 70 to 120° C. In some embodiments, theresulting mixture of water and bitumen-containing solvent is heated to atemperature of from 80 to 110° C.

In some embodiments, an emulsion breaker is added to thebitumen-containing solvent phase prior to mixing or after the mixing ofbitumen-containing solvent and water. Any suitable emulsion breaker canbe used, including but not limited to water soluble or oil solubledemulsifying agents such as amines, amyl resins, butyl resins or nonylresins. The emulsion breaker can help to promote the separation of thebitumen-containing solvent and the water in the desalter.

In step 1200, the mixture of water and bitumen-containing solvent isintroduced into a desalter. The desalter works to remove non-bitumensolid particles from the bitumen-containing solvent, including bothinorganic salts and other materials such as silica and coal particles.Any suitable desalter can be used for carrying out the separation ofsolid particles from the bitumen-containing solvent.

With reference to FIG. 2, a cross-section view of an exemplary desaltersuitable for use in the method described herein is illustrated. As shownin FIG. 2, a mixture of water and bitumen-containing solvent enters thedesalter as an immiscible mixture of water droplets suspended in thebitumen-containing solvent. The vigorous mixing of the water andbitumen-containing solvent prior to introduction of the mixture into thedesalter results in solid particles from the bitumen-containing solventnow being immersed and/or dissolved in the water droplets. A positiveand negative electrode are provided proximate the entry of the mixtureinto the fluid tank of the desalter in order to create an electrostaticfield that induces dipole attractive forces between neighboring dropletsof water. In other words, the electrostatic field results in eachdroplet having a positive charge on one side and a negative charge onthe other. The attractive force generated by the opposite charges onneighboring water droplets causes the water droplets to coalesce. Theresulting larger water globules, along with solids, then settle to thebottom of the fluid tank. The settled water is continuously withdrawnfrom the desalter from a point somewhat above the desalter bottom.

In step 1300, a desalted bitumen-containing solvent stream is removedfrom the desalter. As shown in FIG. 2, the desalted bitumen-containingsolvent is removed from an outlet at the top of the desalter. The outletat the top of the desalter takes advantage of the desaltedbitumen-containing solvent resting on top of the settled water phase andhelps to ensure that predominantly or only desalted bitumen-containingsolvent exits the outlet at the top of the desalter. As shown in FIG. 2,a baffle can also be positioned inside of the desalter to further ensurethat no water droplets or globules end up exiting the desalter via theoutlet of the desalted bitumen-containing solvent phase.

Once the desalted bitumen-containing solvent stream is removed from thedesalter, step 1400 of performing downstream processing on thebitumen-containing solvent stream can be performed with little or noconcern over the downstream processing being negatively impacted bysolid particles contained within the bitumen-containing solvent stream.

Downstream processing of the desalted bitumen-containing solvent streamis not limited and may include any processing steps known and used bythose of ordinary skill in the art. In some embodiments for example,downstream processing can include passing the desaltedbitumen-containing solvent stream through a heat exchanger in order towarm the stream. The removal of solid particles from the stream allowsfor the use of a heat exchanger with reduced or eliminated concernspertaining to fouling the heat exchanger due to solid deposits formingon the walls of the heat exchanger.

In some embodiments, the downstream processing includes use of adistillation tower to separate solvent from bitumen and/or separatefractions of the bitumen component. Atmospheric and/or vacuumdistillation towers can be used. The removal of the solid particles fromthe bitumen-containing solvent stream can be performed prior to thedistillation so that material capable of converting to corrosivematerial (i.e., magnesium chloride capable of converting to HCl due towater hydrolysis) is not present in the distillation towers andassociated condensers.

In some embodiments, the downstream processing includes the cracking andupgrading of the bitumen component of bitumen-containing solvent.Cracking and upgrading can be carried out in, for example, a nozzlereactor. In some embodiments, the desalted bitumen-containing solventprovided by the desalter is injected into a nozzle reactor similar oridentical to the nozzle reactor described in U.S. Pat. No. 7,618,597;U.S. Pat. No. 7,927,565; U.S. Published Application No. 2011/0084000;and U.S. Published Application No. 2011/0308995, each of which is herebyincorporated by reference in its entirety.

FIGS. 4 and 5 show cross-sectional views of one embodiment of a nozzlereactor 100 suitable for use in the methods described herein. The nozzlereactor 100 includes a head portion 102 coupled to a body portion 104. Amain passage 106 extends through both the head portion 102 and the bodyportion 104. The head and body portions 102, 104 are coupled together sothat the central axes of the main passage 106 in each portion 102, 104are coaxial so that the main passage 106 extends straight through thenozzle reactor 100.

It should be noted that for purposes of this disclosure, the term“coupled” means the joining of two members directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two members or the two members andany additional intermediate members being integrally formed as a singleunitary body with one another or with the two members or the two membersand any additional intermediate member being attached to one another.Such joining may be permanent in nature or alternatively may beremovable or releasable in nature.

The nozzle reactor 100 includes a feed passage 108 that is in fluidcommunication with the main passage 106. The feed passage 108 intersectsthe main passage 106 at a location between the portions 102, 104. Themain passage 106 includes an entry opening 110 at the top of the headportion 102 and an exit opening 112 at the bottom of the body portion104. The feed passage 108 also includes an entry opening 114 on the sideof the body portion 104 and an exit opening 116 that is located wherethe feed passage 108 meets the main passage 106.

During operation, the nozzle reactor 100 includes a reacting fluid thatflows through the main passage 106. The reacting fluid enters throughthe entry opening 110, travels the length of the main passage 106, andexits the nozzle reactor 100 out of the exit opening 112. A feedmaterial flows through the feed passage 108. The feed material entersthrough the entry opening 114, travels through the feed passage 106, andexits into the main passage 108 at exit opening 116.

The main passage 106 is shaped to accelerate the reacting fluid. Themain passage 106 may have any suitable geometry that is capable of doingthis. As shown in FIGS. 4 and 5, the main passage 106 includes a firstregion having a convergent section 120 (also referred to herein as acontraction section), a throat 122, and a divergent section 124 (alsoreferred to herein as an expansion section). The first region is in thehead portion 102 of the nozzle reactor 100.

The convergent section 120 is where the main passage 106 narrows from awide diameter to a smaller diameter, and the divergent section 124 iswhere the main passage 106 expands from a smaller diameter to a largerdiameter. The throat 122 is the narrowest point of the main passage 106between the convergent section 120 and the divergent section 124. Whenviewed from the side, the main passage 106 appears to be pinched in themiddle, making a carefully balanced, asymmetric hourglass-like shape.This configuration is commonly referred to as a convergent-divergentnozzle or “con-di nozzle”.

The convergent section of the main passage 106 accelerates subsonicfluids since the mass flow rate is constant and the material mustaccelerate to pass through the smaller opening. The flow will reachsonic velocity or Mach 1 at the throat 122 provided that the pressureratio is high enough. In this situation, the main passage 106 is said tobe in a choked flow condition.

Increasing the pressure ratio further does not increase the Mach numberat the throat 122 beyond unity. However, the flow downstream from thethroat 122 is free to expand and can reach supersonic velocities. Itshould be noted that Mach 1 can be a very high speed for a hot fluidsince the speed of sound varies as the square root of absolutetemperature. Thus the speed reached at the throat 122 can be far higherthan the speed of sound at sea level.

The divergent section 124 of the main passage 106 slows subsonic fluids,but accelerates sonic or supersonic fluids. A convergent-divergentgeometry can therefore accelerate fluids in a choked flow condition tosupersonic speeds. The convergent-divergent geometry can be used toaccelerate the hot, pressurized reacting fluid to supersonic speeds, andupon expansion, to shape the exhaust flow so that the heat energypropelling the flow is maximally converted into kinetic energy.

The flow rate of the reacting fluid through the convergent-divergentnozzle is isentropic (fluid entropy is nearly constant). At subsonicflow the fluid is compressible so that sound, a small pressure wave, canpropagate through it. At the throat 122, where the cross sectional areais a minimum, the fluid velocity locally becomes sonic (Machnumber=1.0). As the cross sectional area increases the gas begins toexpand and the gas flow increases to supersonic velocities where a soundwave cannot propagate backwards through the fluid as viewed in the frameof reference of the nozzle (Mach number>1.0).

The main passage 106 only reaches a choked flow condition at the throat122 if the pressure and mass flow rate is sufficient to reach sonicspeeds, otherwise supersonic flow is not achieved and the main passagewill act as a venturi tube. In order to achieve supersonic flow, theentry pressure to the nozzle reactor 100 should be significantly aboveambient pressure.

The pressure of the fluid at the exit of the divergent section 124 ofthe main passage 106 can be low, but should not be too low. The exitpressure can be significantly below ambient pressure since pressurecannot travel upstream through the supersonic flow. However, if thepressure is too far below ambient, then the flow will cease to besupersonic or the flow will separate within the divergent section 124 ofthe main passage 106 forming an unstable jet that “flops” around anddamages the main passage 106. In one embodiment, the ambient pressure isno higher than approximately 2-3 times the pressure in the supersonicgas at the exit.

The supersonic reacting fluid collides and mixes with the feed materialin the nozzle reactor 100 to produce the desired reaction. The highspeeds involved and the resulting collision produces a significantamount of kinetic energy that helps facilitate the desired reaction. Thereacting fluid and/or the feed material may also be pre-heated toprovide additional thermal energy to react the materials.

The nozzle reactor 100 may be configured to accelerate the reactingfluid to at least approximately Mach 1, at least approximately Mach 1.5,or, desirably, at least approximately Mach 2. The nozzle reactor mayalso be configured to accelerate the reacting fluid to approximatelyMach 1 to approximately Mach 7, approximately Mach 1.5 to approximatelyMach 6, or, desirably, approximately Mach 2 to approximately Mach 5.

As shown in FIG. 5, the main passage 106 has a circular cross-sectionand opposing converging side walls 126, 128. The side walls 126, 128curve inwardly toward the central axis of the main passage 106. The sidewalls 126, 128 form the convergent section 120 of the main passage 106and accelerate the reacting fluid as described above.

The main passage 106 also includes opposing diverging side walls 130,132. The side walls 130, 132 curve outwardly (when viewed in thedirection of flow) away from the central axis of the main passage 106.The side walls 130, 132 form the divergent section 124 of the mainpassage 106 that allows the sonic fluid to expand and reach supersonicvelocities.

The side walls 126, 128, 130, 132 of the main passage 106 provideuniform axial acceleration of the reacting fluid with minimal radialacceleration. The side walls 126, 128, 130, 132 may also have a smoothsurface or finish with an absence of sharp edges that may disrupt theflow. The configuration of the side walls 126, 128, 130, 132 renders themain passage 106 substantially isentropic.

The feed passage 108 extends from the exterior of the body portion 104to an annular chamber 134 formed by head and body portions 102, 104. Theportions 102, 104 each have an opposing cavity so that when they arecoupled together the cavities combine to form the annular chamber 134. Aseal 136 is positioned along the outer circumference of the annularchamber 134 to prevent the feed material from leaking through the spacebetween the head and body portions 102, 104.

It should be appreciated that the head and body portions 102, 104 may becoupled together in any suitable manner. Regardless of the method ordevices used, the head and body portions 102, 104 should be coupledtogether in a way that prevents the feed material from leaking andwithstands the forces generated in the interior. In one embodiment, theportions 102, 104 are coupled together using bolts that extend throughholes in the outer flanges of the portions 102, 104.

The nozzle reactor 100 includes a distributor 140 positioned between thehead and body portions 102, 104. The distributor 140 prevents the feedmaterial from flowing directly from the opening 141 of the feed passage108 to the main passage 106. Instead, the distributor 140 annularly anduniformly distributes the feed material into contact with the reactingfluid flowing in the main passage 106.

As shown in FIG. 7, the distributor 140 includes an outer circular wall148 that extends between the head and body portions 102, 104 and formsthe inner boundary of the annular chamber 134. A seal or gasket may beprovided at the interface between the distributor 140 and the head andbody portions 102, 104 to prevent feed material from leaking around theedges.

The distributor 140 includes a plurality of holes 144 that extendthrough the outer wall 148 and into an interior chamber 146. The holes144 are evenly spaced around the outside of the distributor 140 toprovide even flow into the interior chamber 146. The interior chamber146 is where the main passage 106 and the feed passage 108 meet and thefeed material comes into contact with the supersonic reacting fluid.

The distributor 140 is thus configured to inject the feed material atabout a 90° angle to the axis of travel of the reacting fluid in themain passage 106 around the entire circumference of the reacting fluid.The feed material thus forms an annulus of flow that extends toward themain passage 106. The number and size of the holes 144 are selected toprovide a pressure drop across the distributor 140 that ensures that theflow through each hole 144 is approximately the same. In one embodiment,the pressure drop across the distributor is at least approximately 2000pascals, at least approximately 3000 pascals, or at least approximately5000 pascals.

The distributor 140 includes a wear ring 150 positioned immediatelyadjacent to and downstream of the location where the feed passage 108meets the main passage 106. The collision of the reacting fluid and thefeed material causes a lot of wear in this area. The wear ring is aphysically separate component that is capable of being periodicallyremoved and replaced.

As shown in FIG. 7, the distributor 140 includes an annular recess 152that is sized to receive and support the wear ring 150. The wear ring150 is coupled to the distributor 140 to prevent it from moving duringoperation. The wear ring 150 may be coupled to the distributor in anysuitable manner. For example, the wear ring 150 may be welded or boltedto the distributor 140. If the wear ring 150 is welded to thedistributor 140, as shown in FIG. 6, the wear ring 150 can be removed bygrinding the weld off. In some embodiments, the weld or bolt need notprotrude upward into the interior chamber 146 to a significant degree.

The wear ring 150 can be removed by separating the head portion 102 fromthe body portion 104. With the head portion 102 removed, the distributor140 and/or the wear ring 150 are readily accessible. The user can removeand/or replace the wear ring 150 or the entire distributor 140, ifnecessary.

As shown in FIGS. 4 and 5, the main passage 106 expands after passingthrough the wear ring 150. This can be referred to as expansion area 160(also referred to herein as an expansion chamber). The expansion area160 is formed largely by the distributor 140, but can also be formed bythe body portion 104.

Following the expansion area 160, the main passage 106 includes a secondregion having a converging-diverging shape. The second region is in thebody portion 104 of the nozzle reactor 100. In this region, the mainpassage includes a convergent section 170 (also referred to herein as acontraction section), a throat 172, and a divergent section 174 (alsoreferred to herein as an expansion section). The converging-divergingshape of the second region differs from that of the first region in thatit is much larger. In one embodiment, the throat 172 is at least 2-5times as large as the throat 122.

The second region provides additional mixing and residence time to reactthe reacting fluid and the feed material. The main passage 106 isconfigured to allow a portion of the reaction mixture to flow backwardfrom the exit opening 112 along the outer wall 176 to the expansion area160. The backflow then mixes with the stream of material exiting thedistributor 140. This mixing action also helps drive the reaction tocompletion.

The dimensions of the nozzle reactor 100 can vary based on the amount ofmaterial that is fed through it. For example, at a flow rate ofapproximately 590 kg/hr, the distributor 140 can include sixteen holes144 that are 3 mm in diameter. The dimensions of the various componentsof the nozzle reactor shown in FIGS. 4 and 5 are not limited, and maygenerally be adjusted based on the amount of feed flow rate if desired.Table 1 provides exemplary dimensions for the various components of thenozzle reactor 100 based on a hydrocarbon feed input measured in barrelsper day (BPD).

TABLE 1 Exemplary nozzle reactor specifications Feed Input (BPD) NozzleReactor Component (mm) 5,000 10,000 20,000 Main passage, first region,entry opening 254 359 508 diameter Main passage, first region, throatdiameter 75 106 150 Main passage, first region, exit opening 101 143 202diameter Main passage, first region, length 1129 1290 1612 Wear ringinternal diameter 414 585 828 Main passage, second region, entry opening308 436 616 diameter Main passage, second region, throat diameter 475672 950 Main passage, second region, exit opening 949 1336 1898 diameterNozzle reactor, body portion, outside diameter 1300 1830 2600 Nozzlereactor, overall length 7000 8000 10000

It should be appreciated that the nozzle reactor 100 can be configuredin a variety of ways that are different than the specific design shownin the Figures. For example, the location of the openings 110, 112, 114,116 may be placed in any of a number of different locations. Also, thenozzle reactor 100 may be made as an integral unit instead of comprisingtwo or more portions 102, 104. Numerous other changes may be made to thenozzle reactor 100.

Turning to FIGS. 8 and 9, another embodiment of a nozzle reactor 200 isshown. This embodiment is similar in many ways to the nozzle reactor100. Similar components are designated using the same reference numberused to illustrate the nozzle reactor 100. The previous discussion ofthese components applies equally to the similar or same componentsincludes as part of the nozzle reactor 200.

The nozzle reactor 200 differs a few ways from the nozzle reactor 100.The nozzle reactor 200 includes a distributor 240 that is formed as anintegral part of the body portion 204. However, the wear ring 150 isstill a physically separate component that can be removed and replaced.Also, the wear ring 150 depicted in FIG. 9 is coupled to the distributor240 using bolts instead of by welding. It should be noted that the boltsare recessed in the top surface of the wear ring 150 to prevent themfrom interfering with the flow of the feed material.

In FIGS. 8 and 9, the head portion 102 and the body portion 104 arecoupled together with a clamp 280. The seal, which can be metal orplastic, resembles a “T” shaped cross-section. The leg 282 of the “T”forms a rib that is held by the opposing faces of the head and bodyportions 102, 104. The two arms or lips 284 form seals that create anarea of sealing surface with the inner surfaces 276 of the portions 102,104. Internal pressure works to reinforce the seal.

The clamp 280 fits over outer flanges 286 of the head and body portions102, 104. As the portions 102, 104 are drawn together by the clamp, theseal lips deflect against the inner surfaces 276 of the portions 102,104. This deflection elastically loads the lips 284 against the innersurfaces 276 forming a self-energized seal. In one embodiment, the clampis made by Grayloc Products, located in Houston, Tex.

When a nozzle reactor as described above and/or in one of theaforementioned documents is used, the desalted bitumen-containingsolvent stream leaving the outlet of the desalter can be injected intothe nozzle reactor via a feed material inlet included in the nozzlereactor. The outlet of the desalter can be in fluid communication withthe feed material inlet of the nozzle reactor in order to allow fortransportation of the desalted bitumen-containing solvent stream fromthe desalter to the nozzle reactor. Once injected into the nozzlereactor via the feed material inlet, the desalted bitumen-containingsolvent stream interacts with the cracking material also injected intothe nozzle reactor in order to crack and upgrade the bitumen componentof the bitumen-containing solvent stream. Additional details of thenozzle reactor upgrading process are set forth in the above-mentionednozzle reactor Patents and Applications.

FIG. 3 illustrates a system 300 that can be used in order to carry outthe methods described above. The system 300 includes a mixing vessel310, a desalter 320, and a nozzle reactor 330. In operation, abitumen-containing solvent stream 311 is passed into the mixing vessel310. Water stream 312 is also passed into the mixing vessel 310 so thatthe water stream 312 and the bitumen-containing solvent stream mix. Amixture 313 of water and bitumen-containing solvent leaves the mixingvessel 310 and is passed into the desalter. The desalter works to removesolid particles from the mixture 313 as described in greater detailabove, and ultimately produces a desalted bitumen-containing solventstream 321. The desalted bitumen-containing solvent stream 321 is theninjected into a nozzle reactor 330. A cracking material 331 is injectedinto the nozzle reactor at a direction perpendicular to the desaltedbitumen-containing solvent stream 321 and can be accelerated tosupersonic speed. The cracking material 331 and the desaltedbitumen-containing solvent stream 321 interact inside of the nozzlereactor 330 in order to crack and upgrade the bitumen component of thedesalted bitumen-containing solvent stream 321. Cracked bitumen (i.e.,hydrocarbons that are lighter than the original bitumen) 332 exits thenozzle reactor 330.

The above described processes and methods can be carried out one or moretimes in order to remove a sufficient amount of non-bitumen solidparticles from the bitumen-containing solvent. For example, a series ofdesalters can be provided wherein the bitumen-containing solvent ismoved through each desalter in a series in order to remove sufficientamounts of non-bitumen solid particles. The bitumen-containing solventcan also be run through the same desalter numerous times for achieve asimilar result. In some embodiments, a 90% desalting efficiency isdesirable and can be achieved by using multiple desalting stages.

In some embodiments, the above described processes and systems areutilized in order to provide a bitumen-containing solvent that has lessthan 0.5% BS&W (basic sediments and water). Bitumen-containing solventhaving a BS&W level below 0.5% can be suitable for pipelining and otherdownstream processing. Another measure of solid particles inbitumen-containing solvent is PTB or pounds per 1000 bbls of oil orequivalent sodium chloride in pounds per 1000 bbls oil. In someembodiments, obtaining a PTB below 20 is important for providingbitumen-containing solvent suitable for pipelining and downstreamprocessing.

Unless otherwise indicated, all numbers or expressions, such as thoseexpressing dimensions, physical characteristics, etc. used in thespecification are understood as modified in all instances by the term“approximately.” At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the claims, each numericalparameter recited in the specification or claims that is modified by theterm “approximately” should at least be construed in light of the numberof recited significant digits and by applying ordinary roundingtechniques. Moreover, all ranges disclosed herein are to be understoodto encompass and provide support for claims that recite any and allsubranges or any and all individual values subsumed therein. Forexample, a stated range of 1 to 10 should be considered to include andprovide support for claims that recite any and all subranges orindividual values that are between and/or inclusive of the minimum valueof 1 and the maximum value of 10; that is, all subranges beginning witha minimum value of 1 or more and ending with a maximum value of 10 orless (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1to 10 (e.g., 3, 5.8, 9.9994, and so forth).

1. A method of removing material from bitumen-containing solvent, thematerial removing method comprising the steps of: (i) providing abitumen-containing solvent stream; (ii) mixing the bitumen-containingsolvent stream and a water stream; (iii) introducing the mixture of thebitumen-containing solvent stream and the water stream in a desalter toremove solid particles from the mixture; (iv) removing a desaltedbitumen-containing solvent stream from the desalter; and (iv) subjectingthe desalted bitumen-containing solvent stream to downstream processing.2. The material removing method as recited in claim 1, wherein thebitumen-containing solvent stream provided in step i) comprises from 0to 35% solvent and from 100 to 65% bitumen.
 3. The material removingmethod as recited in claim 2, wherein the solvent component of thebitumen-containing solvent stream comprises an aromatic solvent, aparaffinic solvent, or a polar solvent.
 4. The material removing methodas recited in claim 1, wherein the bitumen-containing solvent streamcomprises inorganic salts.
 5. The material removing method as recited inclaim 1, wherein prior to processing the mixture in the desalter, themixture is heated to a temperature in the range of from 80 to 120 ° C.6. The material removing method as recited in claim 1, wherein prior tomixing the bitumen-containing solvent stream and the water stream, thebitumen-containing solvent stream is heated to a temperature in therange of from 100 to 140° C.
 7. The material removing method as recitedin claim 1, wherein the mixture includes from 0 to 35%bitumen-containing solvent and from 1 to 25% water.
 8. The materialremoving method as recited in claim 1, further comprising adding anemulsion breaker to the mixture.
 9. The material removing method asrecited in claim 8, wherein the emulsion breaker comprises amines, amylresins, butyl resins, and mixtures thereof.
 10. The material removingmethod as recited in claim 1, wherein the bitumen-containing solvent isobtained from a SAGD process.
 11. The material removing method asrecited in claim 1, wherein the bitumen-containing solvent is obtainedfrom a double solvent extraction process.
 12. The material removingmethod as recited in claim 1, wherein the bitumen-containing solvent isobtained from an in-situ extraction process.
 13. The material removingmethod as recited in claim 1, wherein the bitumen-containing solvent isobtained from a single solvent extraction process.
 14. The materialremoving method as recited in claim 1, wherein the downstream processingcomprises distillation of the desalted bitumen-containing solventstream.
 15. The material removing method as recited in claim 1, whereinthe downstream processing comprises cracking of the bitumen content ofthe desalted bitumen-containing solvent stream in a nozzle reactor. 16.A method of removing material from bitumen-containing solvent, thematerial removing method comprising the steps of: (i) providing abitumen-containing solvent stream; (ii) mixing the bitumen-containingsolvent stream and a water stream; (iii) introducing the mixture of thebitumen-containing solvent stream and the water stream in a desalter toremove solid particles from the mixture; (iv) removing a desaltedbitumen-containing solvent stream from the desalter; and (iv) upgradingthe desalted bitumen-containing solvent stream in a nozzle reactor. 17.The material removing method as recited in claim 16, wherein the nozzlereactor comprises: a reactor body having a reactor body passage with aninjection end and an ejection end; a first material injector having afirst material injection passage and being mounted in the nozzle reactorin material injecting communication with the injection end of thereactor body passage, the first material injection passage having (a) anenlarged volume injection section, an enlarged volume ejection section,and a reduced volume mid-section intermediate the enlarged volumeinjection section and enlarged volume ejection section, (b) a materialinjection end in material injecting communication with the combustionchamber, and (c) a material ejection end in material injectingcommunication with the reactor body passage; and a second material feedport penetrating the reactor body and being (a) adjacent to the materialejection end of the first material injection passage and (b) transverseto a first material injection passage axis extending from the materialinjection end to the material ejection end in the first materialinjection passage in the first material injector;
 18. A system forremoving material from bitumen-containing solvent, the material removingsystem comprising: a desalter having a bitumen-containing solvent streaminlet and a desalted bitumen-containing solvent stream outlet; and anozzle reactor having a feed material inlet, wherein the feed materialinlet is in fluid communication with the desalted bitumen-containingsolvent stream outlet of the desalter.
 19. The material removing systemas recited in claim 18, wherein the structure of the nozzle reactorcomprises: a reactor body having a reactor body passage with aninjection end and an ejection end; a first material injector having afirst material injection passage and being mounted in the nozzle reactorin material injecting communication with the injection end of thereactor body passage, the first material injection passage having (a) anenlarged volume injection section, an enlarged volume ejection section,and a reduced volume mid-section intermediate the enlarged volumeinjection section and enlarged volume ejection section, (b) a materialinjection end in material injecting communication with the combustionchamber, and (c) a material ejection end in material injectingcommunication with the reactor body passage; and a second material feedport penetrating the reactor body and being (a) adjacent to the materialejection end of the first material injection passage and (b) transverseto a first material injection passage axis extending from the materialinjection end to the material ejection end in the first materialinjection passage in the first material injector;
 20. The materialremoving system as recited in claim 18, further comprising: a mixingvessel having a water inlet, a bitumen-containing solvent stream inlet,and a bitumen-containing solvent stream outlet, wherein thebitumen-containing solvent stream outlet of the mixing vessel is influid communication with the bitumen-containing solvent stream inlet ofthe desalter.